Tandem compacting and molding apparatus with continuous inverted flask removal

ABSTRACT

A molding apparatus with a closed loop conveyor mounted on a conveyor frame consisting of a plurality of consecutively connected pattern-carrying carts wherein tandem compacting rollers are provided above the conveyor for consecutively compacting at different compacting pressures mold material deposited in flasks positioned on each of the moving patterncarrying carts. Additional mold material may be supplied to the moving carts at a point between the compacting rollers. Removal of the flasks from the pattern-carrying carts is provided for on the underneath or bottom portion of the conveyor. There, means are provided with each cart to permit the downward drawing of the flask, previously temporarily secured and retained to the cart in the form of clamping yokes, away from the cart in aligned relation to a lowered position below the level of the cart during which the flask is supported by the clamping yokes. Means to release the drawing means is provided to operate as each cart commences its travel along the conveyor bottom portion. Means may further be provided to control the rate of downward descent of the flask during the drawing operation.

United States Patent [191 Stale'y I t 1 TANDEM COMPACTING AND MOLDING APPARATUS WITH CONTINUOUS INVERTED FLASK REMOVAL [75] Inventor: John Staley, New Port Richey, Fla.

[73] Assignee: G & G industries, Inc., Pittsburgh,

[22] Filed: Feb. 27, 1973 [21] Appl. No.: 336,275

[52] US. Cl 164/194, 164/208, 164/210, 164/18 [51] Int. Cl. B22c 115/02 [58] Field of Search 164/18, 181, 194, 208, 164/210; 425/345 [56] References Cited UNITED STATES PATENTS v 854,932 5/1907 Dages 164/210 X 865,511 9/1907 Mehaffey 164/208 1,008,207 11/1911 Simpson 164/210 X 2,317,574 4/1943 Williams 164/181 3,628,593 12/1971 Staley 164/208 3,672,434 6/1972 Grolla 164/210 X FOREIGN PATENTS OR APPLICATIONS 348,419 5/1931 Great Britain 164/210 Primary Examiner-R. Spencer Annear Attorney, Agent, or Firm-Carothers & Carothers [57] ABSTRACT A molding apparatus with a closed loop conveyor mounted on a conveyor frame consisting of a plurality of consecutively connected pattern-carrying carts wherein tandem compacting rollers are provided above the conveyor for consecutively compacting at different compacting pressures mold material deposited in flasks positioned on each of the moving pattern-carrying carts. Additional mold material may be supplied to the moving carts at a point between the compacting rollers.

Removal of the flasks from the pattern-carrying carts is provided for on the underneath or bottom portion of the conveyor. There, means are provided with each cart to permit the downward drawing of the flask, previously temporarily secured and retained to the cart in the form of clamping yokes, away from the cart in aligned relation to a lowered position below the level of the cart during which the flask'is supported by the clamping yokes. Means to release the drawing means is provided to operate as each cart commences its travel along the conveyor bottom portion, Means may further be provided to control the rate of downward descent of the flask during the drawing operation.

20 Claims, 11 Drawing Figures I l TANDEM COMPACTING AND MOLDING APPARATUS WITH CONTINUOUS INVERTED FLASK REMOVAL BACKGROUND OF INVENTION This invention relates generally to a continuous molding apparatus and more particularly to such moldcope or drag flask in which the molding material is deposited and subsequently passed under a compacting means to bring about formation of a mold to the confines of the pattern positioned usually on the cart. The loop conveyor in general is supported at its ends by means of rollers or sprockets so that the flask containing the molded material is removed from the continuously moving conveyor after passing the compacting means. The conveyor then moves on to the position of the end sprocket wherein the pattern conveyor is inverted for sequential return of the pattern carts to be reinverted for filling a deposited flask again with the molding material.

ln the case of U.S. Pat. No. 854,932, however, the cope or drag flask is inverted with the pattern cart as the latter is moved to a flask removing station positioned below the bottom portion of the moving conveyor.

It has also been known, such as shown in U.S. Pat. Nos. 400,893; 1,072,229 and 1,759,728, to provide compacting roller means either in the form of one or two rollers, the latter being placed in tandem,.to compress initially the molding material in the flask and thereafter again compress with a second roller. by having it adjusted to be lower or closer to the flask contain ing the molding material.

With the employment of one compacting roller means, hydraulic means can be employed to apply compacting pressure to molding material within the flask to selectively vary the mold material hardness as shown in my previous U.S. Pat. No. 3,628,593 (164/208) of Dec. 21, 1971.

In cases where the flask containing the finished mold is inverted either at a single station, such as shown in U.S. Pat. No. 1,948,799, or in the case ofa moving pattern cartconveyor, such as shown in U.S. Pat. No. 854,932, it is known to use an L-shaped hook or clamping yoke to hold the flask engaged to the pattern cart.

veyor type are not truly continuous. For example, the

molding machines of U.S. Pat. Nos. 854,932 and 1,343,386 operate on an intermittent basis. Furthermore, in U.S. Pat. No. 854,932, although the flask is inverted as it travels along the bottom portion of the closed loop conveyor, it has to be stop-positioned over an upwardly presented flask support thereby necessitating some means to insure removal of the flask containing its mold from the pattern cart. No means are provided on the pattern cart to assist in the removal of the flask when in such an inverted position while simultaneously insuring that the separation or draw of the cart and flask is accomplished in an aligned and careful, but continuous, manner so as not to jar or otherwise accidentally cause chips or breaks in the patternshaped mold, which is usually still in the stage of hardening or curing.

SUMMARY OF THE lNVENTlON This invention principally relates to a novel molding apparatus that is truly continuous in operation by providing a closed loop conveyor consisting of a series of pattern carts adapted to receive a flask which is filled with molding material whereupon the material-filled flask is passed beneath a pair of compacting rollers with means provided therebetween to deposit additional molding material into the flask. The surfaces of the compacting rollers are provided with special tamping feet to achieve the desired mold hardness particularly necessary where deep draw patterns are involved, all accomplished without the aid of special pressure or hydraulic means, which means necessitate periodic adjustment to obtain the desired compacting pressure for a particular pattern and molding material situation.

Another principal feature of the present invention is' the provision of both means for securing and retaining the flask firmly to the pattern cart and means for permitting gradual downward and aligned drawing of the flask from the pattern cart when the same have been inverted for travel along the bottom portion of the closed loop conveyor. The securing and drawing means are adapted to permit the flask to draw downwardly when so inverted, but the rate of draw is cushioned and controlled by means of air cylinders having an adjustable but restricted air exhaust.

After the draw has been completed, that is, the flask held by the securing and drawing means has permitted the flask to be in the lowest position below its accompanying pattern cart, the securing means, which have held the flask in engagement with the pattern cart and thereafter supported the flask during its downward travel or draw, are cammed to clear the flask. The flask at this position, due to continuous travel of the conveyor, has engaged the surface of a second or draw conveyor for transporting the flask to the next foundry station. From the foregoing, it can readily be seen that at no time is the flask dropped or removed abruptly from the pattern cart to the removal conveyor, but rather is deposited on the draw conveyor in a continuous but gentle sweeping motion, while the closed loop conveyor continues to operate.

Another object of the present invention is the provision of a means to withdraw or disengage the securing means from their position of retaining the flask when the same is deposited on the draw conveyor beneath the moving loop conveyor as well as means to align the securing means for clamping engagement of the flask when the same has been deposited from the top portion of the loop conveyor on a moving pattern cart.

Another object of the present invention is the provision of means to release the drawing means to permit Another object of the present invention is the provision of means to lock the drawing means in extended position from the pattern cart to securely retain the flask in engagement on the cart until the latter is inverted and the releasing means, again releases the drawing means to permit the downward draw of the flask. The same counterweight and latch bar as already mentioned may be used to perform the locking function.

Another object of the present invention is the provision of two molding apparatus each having tandem compacting rollers with each apparatus in side-by-side relation so that one molding apparatus is producing a mold in the cope flask while the other molding apparatus is producing a mold in the drag flask, so that upon depositing of the cope and drag flasks on the adjacent draw conveyors of the molding apparatus, the flask members may be properly joined together and forwarded on to the next foundry station.

Another object of the present invention is the provision of a molding apparatus which includes automatic and continuous removal of flasks from the bottom portion of a moving loop conveyor from a plurality of inverted pattern carts with the compacting molding materials deposited in the flasks at the top portion of the moving loop conveyor thereby providing a completely automatic molding apparatus from the time of flask presentation up to and including flask removal, taking up a minimum of foundry space.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages appear in the following description and claims.

The accompanying drawings show, for the purpose of exemplification without limiting the invention or the claims thereto, certain practical embodiments illustrating the principles of this invention wherein:

FIG. 1 is a side elevation of the tandem compacting and molding apparatus comprising this invention including means for continuous inverted flask removal.

FIG. 2 is a plan view of the apparatus shown in FIG.

FIG. 3 is an end view of the apparatus shown in FIG. I, with parts in section, showing the addition of a substantially identical apparatus in adjacent or side-by-side relation to perform a continuous molding operation on opposite but mating flask pieces.

FIG. 4 is a side elevation of a single pattern cart from the series of such carts making up the closed loop conveyor.

FIG. 5 is a plan view of the pattern cart of FIG. 4.

FIG. 6 is an end view of the pattern cart of FIG. 4.

FIG. 7 is a sectional view taken along the line 7-7 of the apparatus shown in FIG. 1.

FIG. 8 is a sectional view taken along the line 8-8 of the apparatus shown in FIG. 1.

FIG. 9 is a sectional view taken along the line 9-9 of the apparatus shown in FIG. 1.

FIG. 10 is a sectional view taken along the line 10-10 of FIG. 7.

FIG. 11 is a sectional view taken along the line 11-11 of FIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIGS. 1, 2 and 3, the molding apparatus 1 comprises a base frame 2 upon which is supported a horizontal conveyor frame 3 having a top portion 4 and a bottom portion 5. The frame 2 is supported on the base 6 and includes the structural uprights 7, which not only aid in the support of the horizontal conveyor frame 3, but also support the means for compaction of the molding material deposited in the mold flask which will be explained in greater detail later on.

The horizontal conveyor frame 3 can be constructed in any suitable manner. As shown in FIG. 3, the top portion 4 consists of the box frame element 8 upon which the conveyor track 10 is secured. However, upon reference to both FIGS. 1 and 3, it can be seen that the end portions 11 as well as the bottom portion 5 of the conveyor frame 3 consists of two right-angle members 12 as a means of guidance for and retainment of the closed loop conveyor 13 in its travel around the end portions 11 and the bottom portion 5.

The closed loop conveyor 13 essentially consists of a plurality of consecutively connected pattern-carrying carts 14. The carts 14 are connected together by means of a pair of conveyor chains 15 so that the closed loop conveyor 13 may be moved along the conveyor frame 3 by means of a pair of motor driven chain sprockets 16 positioned at the left end portion 11L of the conveyor frame 3. A pair of idler sprockets 17 are positioned at the right end portion 11R of the conveyor frame 3 as clearly shown in FIGS. 1 and 3. It is by no means inconveivable that both pairs of sprockets l6 and 17 may be simultaneously motor driven.

Generally, each of the pattern carts 14 consists of the cart frame 18, two pairs of rollers or wheels 20, and means for securing a pattern 21 to the frame 18. Flask alignment pins 22 are provided on the upper surfaces of the cart 18 to receive corresponding openings in the frame of a flask 23 deposited on the top of the cart frame 18. Further details concerning the patterncarrying carts 14 will be given later.

Upon review of FIG. 1, in particular, it can be seen that if the closed loop conveyor 13 is driven in the direction of the arrows 24, each of the pattern-carrying carts 14 pass through a number of operations from a position of first depositing a flask 23 on the cart frame 18 to a position where the flask containing a finished mold is gently deposited on a second or draw conveyor directly beneath the bottom portion 5 of the conveyor 13.

As shown in FIG. 1, the flasks 23 are delivered along the flask conveyor 25 to a point wherein they are aligned with the cart alignment pins 22 and deposited consecutively on each cart 14. Upon performing this operation, molding material is supplied from a first molding material hopper shown at 26 to fill the flask 23 aligned and positioned on the pattern-carrying cart 14.

Upon movement of the conveyor 13, the flask is directed to be positioned directly beneath a first compacting roller 27 having disposed uniformly along its arcuate surface 28 a plurality of arcuate compacting feet 30. Each compacting foot 30 has a plurality of Iongitudinal compacting ribs 31 which extend in a direc tion transverse to the direction of travel of the conveyor 13. The compacting ribs 31 not only produce greater compacting pressure upon the molding material already deposited in the flask 23, but also apply a diversified pressure to the molding material, that is, to apply transversely-directed pressure as well as downwardlydirected pressure on the molding material.

As the carts 14 move along the top portion 4 of the conveyor frame 3, additional molding material is supplied to the flask 23 by means of the second molding material hopper 32. The carts 14 then are directed to pass directly beneath a second compacting roller 33 also having uniformly along its circumferential surface a plurality of arcuate compacting feet 34. However, feet 34 are not provided with the compacting ribs such asshown at 31, but rather with a sprew bowl forming shape 35, such as in the preparation of the cope flask. From this point, the flasks 23 with the finallycompacted molding material on each of the carts l4 begins its path of movement about the left end portion 11L of the conveyor frame 3. I

Although not shown in FIG. l,a strike off bar may be provided after each compacting roller 27 and 33 for the purpose of removing any excess mold material on the top of the flask. The employment of strike off bars is illustrated in my prior US. Pat. No. 3,628,593.

As shown more clearly in FIG. 2, compacting roller 27 is supported on a shaft 36. The shaft 36 is supported by means of suitable bearings in the uprights 7. The uprights 7 are maintained in fixed relation by the upper cross member 37 and bracing members 38. This provides for a sturdy structure for supporting both compacting rollers 27 and 33.

Again referring to FIG. 2, the second compacting roller 33 is supported by means of shaft 40, in suitable bearings provided in the uprights 7. Both shafts 36 and 40 also extend into the motor drive frame 41 which supports the drive motor 42 and is coupled by means of the clutch 43 to the gear reducer drive 44. The gear reducer drive 44, in turn, rotatably drives the shaft 45 supported in suitable bearings on the motor drive frame 41. Three gear sprockets 46, 47 and 48 are secured to the gear reducer drive shaft 45. Sprocket 48 is-connected to drive the larger sprocket 50 secured on roller shaft 40 by means of the drive chain 51, whereas sprocket 47 secured on roller shaft 36 is connected to drive the larger drive sprocket 52 by means of the interconnecting drive chain 53. Sprocket 46 drives gear sprocket 54 by means of the drive chain 55. From FIG. 3, it can be seen that sprocket 54 is secured to shaft 56 and, in the particular embodiment shown, shaft 56 is connected to drive the pairs of sprockets 17 which drive the pair of conveyor chains of the molding apparatus 1.

From the foregoing description, it can be seen that upon proper selection of sprocket sizes, the synchronization or time correlation of the rotary velocity of each of the compacting rollers 27 and 33 and the linear velocity of the conveyor 13 can readily be accomplished so that these corresponding velocities are equal. With the distance between the consecutive or adjacent carts 14 also being taken into consideration, upon operation of the conveyor 13, each cart 14 supporting a flask 23 will be properly aligned so that a compacting foot 30 or 34, whichever is the case, will be properly positioned within the confines of the flask 23 for proper compacting engagement with the molding material deposited within the flask to compact the molding material against the pattern 21.

Reference is made to the structure shown in FIG. 3, wherein two molding apparatus 1 are shown in side-byside relation. Shaft 56 is a common shaft for both machines for the purpose of driving the two pairs of end sprockets 17 of the two separate conveyors 13. With such an arrangement of two molding apparatus 1, one such apparatus can be performing the molding operation with regard to the cope flask whereas the other molding apparatus can be performing the molding operation relative to the drag flask.

Reference is now made to the bottom portion of FIG. 1, wherein each of the consecutively connected pattern-carrying carts 14, upon circling around the left end portion 11L of the molding apparatus 1, are retained within the confines of the pair of track members 12 to proceed along the bottom portion 5 of the closed loop conveyor 13. At this point, it will be noted that 'each of the flasks 23 positioned on each of the respective carts 14 is held in secure engagement therewith. For purposes of clarity in describing the overall apparatus, the means for securing as well as drawing and removing of the inverted flask 23 along the bottom portion of the conveyor frame 3 is not shown in FIG. 1. These structural apparatus and features are clearly shown in FIGS. 4 through 9, which will be explained hereinafter. However, it can be seen upon viewing FIG. 1, that the flasks 23 are lowered in aligned relationship relative to its respective pattern-carrying cart 14 to be finally placed on a draw or flask removal conveyor 57..

Thus, the flask identified in FIG. 1 along the bottom portion 5 as 23A still remains engaged to its respective pattern-carrying cart 14 through securing means adapted to retain the flask in such an engaged position. By the time that this particular cart has reached the position shown in connection with the flask identified as 23B, means forming part of the cart 14 commences the downward drawing of the flask 23B away from the pattern-carrying cart in aligned relation to a lowered position below the cart while being supported by the securing means. The position of the flask identified at 23C is the lowered position for the flask, at which time the flask has engaged the draw conveyor 57. At this time additional means is operative to withdraw the securing means from their position of retaining the flask 23C. The cart 14 is then permitted to travel along with conveyor 13 leaving the flask 23C on the draw conveyor 55 to be moved on to the next station of the foundry operation.

The relative position of the respective flasks 23A,

23B and 23C is shown in specific detail, respectively,

in FIGS. 7, 8 and 9.

Reference is now made to FIGS. 4, 5 and 6, wherein there is shown the detail structure comprising the pattern-carrying carts 14, each of which includes the securing means, the drawing means, the releasing means, mentioned above, as well as means to control the rate of downward descent of the flasks upon operation of the releasing means.

As previously mentioned, each cart has a frame 18 supported for rolling movement by means of the two pairs of wheels 20, each pair secured together by means of a shaft 58. Cart 14 is also provided with four vertically secured tubular members or sleeves 60 in quadrangular position. The sleeves 60 are adapted to slidably receive the rods 61, which form part of the securing and drawing means. The upper end of the rods 61 are provided with the clamping yokes 62 which have an extending nose portion 63 adapted to engage the bottom flange 64 of each flask 23 to hold the same in engagement to the pattern plate 65 of each patterncarrying cart 14. Thus, each of the clamping yokes 62 form themajor portion of the securing means for holding a flask 23 in retained engagement to the pattern plate 65 of each pattern-carrying cart 14.

The other ends of the drawing rods 61 are connected to the draw support frame 67. Draw support frame 67 consists of a centrally aligned plate member 68, the ends of which are secured to the channel members 70. The ends of the channel members 70 are, in turn, each adapted to receive a threaded end of the draw rod 61, which are secured in position by means of the upper and lower adjusting nuts 71 and 72. Rubber bushings at 73 may be provided for a cushioning effect and more particularly provide some resilience in final locking of the frame 67 in extended position from the cart as will be explained in detail later on.

The very end of each of the rods 61 is provided with arm members 74 and 75. The arm members 74 and 75 are secured by means of a key adapted to be received in slot 76 in the ends of each of the draw rods 61. From the foregoing, it can be readily seen that upon rotation of the arm members 74 and 75, the draw rods 61 will be caused to rotate so that the extended portions 63 of clamping yokes 62 are withdrawn from beneath the bottom flange 64 of the flask.

Located centrally within the cart frame 18 there is the cylinder and piston arrangement 77 with piston rods 78 extending downwardly therefrom for pivotal attachment to plate member 68 at 80.

Cam guide 81 is secured to the bottom of plate 68 and is provided with a cam track 82. Secured to the conveyor frame 3 is cam roller 84 which is positioned in the top portion 4 along the conveyor frame 3. The purpose of the guide 81 is to insure that the draw support frame 67 is in its extended-most position away from the cart 14 so that the means to lock the frame 67 in this position is assured.

As shown in FIGS. 4 through 6, the cart frame 18 includes a pair of support members 85 to not only strengthen construction of the pattern cart 14 but also to provide a means to which is attached the pair of latch bars 86, which are pivotally secured to the plate members 85 at 87. Each latch bar 86 is provided with a counterweight 88 which is secured to the latch bar in a substantially perpendicular position by means of the rod 90. As shown in FIG. 6, each latch bar 86 is provided with a corresponding counterweight 88. Also, in order to insure that the pair of pivotally connected latch bars 86 move together, they are secured in parallel relation by means of the cross bar 91.

From FIGS. 4 and 6, it is clear that the ends of the latch bars 86 are provided with a shoulder 92. The shoulders 92 are adapted to be received in a pair of openings or slots 93 formed in the frame plate 68. The shoulders 92 form an extended portion 94 at the end of each of the latch bars 86 so that the extended portion 94 will extend through corresponding slot 93 due to the weight of counterweight 88 and thus bring the shoulder 92 of each latch bar into engagement with the edge of the slot 93 as depicted in FIG. 4.

From the foregoing description, it can be seen that when the pattern-carrying carts 14 move upwardly around the right end portion 11R of the conveyor 13, the draw rods 61 will slide downwardly to the position such as shown in FIG. 4 due to the weight of the draw support frame 67. The draw support frame 67 will be held and retained in this position by means of the pair of latch bars 86 provided with each pattern-carrying cart 14. This is due to the fact that the counterweight 88 will pivot, as indicated by arrow 99, the end portions 94 of the latch bars 86 into the corresponding pair of slots 93 provided in the plate 68. As the result, the shoulders 92 of the pair of latch bars 86 are maintained in engagement with the edge of the pair of slots 93. The end portions 94 of the latch bars 86 are insured to drop into the slots 93 due to the provision of the cam roller 84 traveling along the surface of the cam track 82 of cam guide 81 as the pattern-carrying cart 14 proceeds along the top portion 4 of conveyor frame 3. It should be readily seen that as each consecutive patterncarrying cart 14 moves downwardly around the left end portion 11L of the conveyor frame 3 as depicted in FIG. 1, the pair of latch bars 86 being held within the slots 93 will maintain the draw support frame 67 in its extended position away from the cart 14 as shown in FIG. 4. However, after the cart has reached the position depicted in FIG. 7 or shown in FIG. 1 in connection with flask 23A, the counterweight 88 will be operative to pivot the pair of latch bars 86 in a direction indicated by arrow 95 in FIG. 4. The result is that the extended portion 94 will maintain the bar 86 within the slot 93 but due to the longitudinal length of the slot 93, the entire dimensional width of the bar including shoulder 92 will be permitted to extend into the respective slot 93. In this manner, the entire draw support frame 67 is released with the draw rods 61 permitted to slide through the sleeves and permit the drawing downwardly of the flask 23 as depicted in FIGS. 8 and 9. In this connection, reference is first made to FIG. 7, wherein there is shown the latch bars 86 secured in a position to hold the draw support frame 67 in its extended position from the cart 14 with the end portions 94 of the latch bars extending through the slots 93. However, due to counterweights 88, the latch bars 86 are caused to pivot in the direction of arrow 95, as indicated in connection with FIG. 4, so that by the time the cart 14 has reached the position of flask 238 as shown in FIGS. 1 and 8, the latch bars 68 have extended through the slots 93 permitting the lowering of the draw support frame 67 as shown in FIG. 8. The flask 238 has dropped a distance below its cart 14 measured by arrow 97. As can be clearly seen in that Figure, the clamping yokes 62 adapted to retain the flask to its respective pattern-carrying cart now function to support the now inverted flask 23B during the drawing operation.

At this point, mention should be made as to the function of the cylinder and piston arrangement 77. This arrangement consists of an air cylinder wherein an exhaust port means in the form of exhaust port 96 is connected directly to the cylinder interior, which limits the rate of expulsion of air from within the cylinder upon drawing of the flask 23 from the cart 14. In this manner, the downward drawing of the respective flask 23 is done in a slow but safe and gentle manner so as not to injure or otherwise accidentally destroy the formed mold within the flask.

In FIG. 9, the flask identified as 23C has dropped to the lowered position and is resting on the surface of the draw conveyor. The flask 23C in this lowered position is separated from the cart 14 by the distance indicated by the arrow 98.

With the flask 23C resting on the conveyor 57, it is necessary that the pairs of clamping yokes 62 be rotated'so that their ends or extended nose portions 63 are withdrawn from a position underneath the bottom flange 64. If the conveyor frame 3 as well as the draw conveyor 57 are of sufficient length, one could assume that each deposited flask 23 on the conveyor 57 is then immediately moved to the next foundry station. The withdrawing of the camming yokes 62 could readily be accomplished by synchronizing the speed of the conveyor 13 to be faster than that of the conveyor 57 so that the extended portion 63 of the clamping yoke 62 will merely pass on from beneath the bottom flange 64 thereby not interfering with the subsequent movement of the flasks along the draw conveyor 57. However, this becomes practically impossible in view of the close relationship of the consecutively arranged plurality of pattern-carrying carts 14. From a practical standpoint, it is best to provide for camming means to rotate the individual draw rods 61 so that the extended portion 63 of each of the camming yokes 62 is rotated approximately 90 to withdraw the extended portion 63 from underneath the bottom flange 64 of the flask 23. This rotational movement is depicted in FIGS. 9 and 11 wherein the camming yokes 62 have been properly rotated out from beneath the bottom flange 64. Thus, the flask 23C is free to move along conveyor 57 while the respective pattern-carrying cart 14 can depart therefrom traveling along the bottom portion of the conveyor frame 3 and thus eventually around the right end portion 11R as shown in FIG. 1.

As further shown in FIG. 1, camming means are provided on the conveyor frame 3 at a point approximately shown at 100 in the bottom portion 5 and also at a point approximately shown at 101 in the top portion 4. Thus, by reference to FIG. 10, it can be seen that as the inverted pattern-carrying cart 14 approaches the cam member 100, a force is applied in the direction of arrow 102 against the cam arm 75 causing it to rotate as indicated. In like manner, extended portion 63 of the camming yoke is also rotated as indicated to a position as shown in FIG. 11. The cam arms 74 and 75, together with the clamping yoke 62 remain in the position shown in FIG. 11 until the pattern-carrying cart 14 has rounded the right end portion 11R of the conveyor frame 3 whereupon cam arm 74 will eventually come in contact with camming member 101 which will apply a force in the direction indicated by the arrow 103 to rotate cam arm 74 together with its accompanying draw rod 61 in the direction indicated to realign the end portion 63 of the camming yoke 62 under the bottom flange 64 of a flask 23 positioned on the alignment pins 22 of the pattern-carrying cart 14.

The relative angular relation of the cam members 74 and 75 in FIGS. and 11 is shown to be approximately 90 for purposes of explanation. However, in actual practice, it hasbeen found that their angular relation should be less than 90.

The function and operation of the molding apparatus 1 has been explained with the detail description of the apparatus in order to have a better immediate understanding of the overall apparatus. However, a brief description of the operation is now made from its beginning step to its end step.

With reference to FIG. 1, operation motor 42 drives in synchronized relation the conveyor 13 in combination with the compacting rollers 27 and 33 so that the compacting feet 30 and 34 are aligned to compress within the flask 23 as each such flask is moved beneath the respective roller.,As each pattern-carrying cart 14 moves upwardly around the right end portion 11R, the delivery conveyor 25 brings into position a flask 23 which can be positioned manually on each of the carts 14 through the employment of the alignment pins 22. Upon operation of the first molding material hopper 26, sufficient amount of molding material is deposited in the flask 23 as the conveyor 13 continues to move. The flask then becomes properly positioned under the first compacting roller 27 wherein one of the arcuate compacting feet 30 with its accompanying compacting rib 31 compresses the molding material down against the surface of the pattern 21 as well as against the sides of the flask. As the cart 14 continues to move, additional molding material is deposited into the flask 23 by means of the second molding material hopper 32, after which the cart 14 is passed under the second compacting roller, and one of the arcuate compacting feet 34 further compresses the molding material within the flask 23.

During this sequence of events occuring on the top portion 4 of the conveyor frame 3, the securing means in the form of the clamping yokes 62 have been properly cammed into position on the bottom flange 64 of the flask 23 as depicted in FIG. 6. Thus, as the cart 14, now with the molding material compressed therein and in the process of curing, is brought around the left end portion 11L in a manner to invert the pattern-carrying cart 14 as well as the flask 23 which is securely held in position on the pattern plate 65 by the clamping yoke 62. The cart 14 continues to move along the double track bottom portion 5 and upon reaching the position of the flask identified as 23A in FIG. 1, the weight of the counterweights 88 of the cart are sufficient to cause slight pivoting movement of the latch bars 86 in the direction of arrow in FIG. 4, thereby removing the shoulders 92 of the latch bars away from the edge of the slots 93 so that the end portions 94 of the latch bars 92 are actually resting against the opposite side of the slots 93. This permits the latch bars to extend upwardly through the slots 93. Therefore, the latch bars, acting as releasing means, permit the downward movement of the flask 23 in proper aligned position by means of the draw rods 61 supported from the draw support frame 67. In this connection, reference is made to FIG. 8, wherein the draw bars 86 are shown extending through the draw support frame plate 68 and the flask 238 has thereby been allowed to descend a distance indicated by the arrow 97. The sleeves 60 being of sufficient length, insure that the guide bars 61 permit the downward drawing of the flask 23 in a perfectly aligned manner relative to the cart 14 and its pattern 21, thereby assuring proper separation of the mold from the pattern.

Inorder to prevent the immediate dropping of the draw support frame 67 to its lower position, the piston 100, thereby rotating the draw rods 61 to the position as shown in FIG. 9. At this time the flask 23C has already obtained its lowered position, a distance of separation from the pattern plate 65 as identified by arrow 98 in FIG. 9. At this lowered position, the flask 23C is already resting on the surface of the draw'conveyor 57 so that the camming yokes may merely be rotated out from beneath the bottom flange 64 of the flask 23. The flask with its finished mold then proceeds along conveyor 57 while conveyor 13 proceeds continuously forward along the bottom portion 5 of the conveyor frame 3 and then upwardly around the right end portion 11R to the position where it again receives another flask 23 aligned on the cart 14 by means of the alignment pins 22. After receiving the flask 23, the cart 14 passes the cam members 101 which are applied against the cam arms 74 as shown in FIG. 11 so as to again bring the extended nose portion 63 of each of the clamping yokes 62 into alignment underneath the bottom flange 64 of the flask 23.

Relatively, at the same time, cam roller 84 is caused to engage the cam track 82 of the cam guide 81 secured to the bottom of the draw support frame plate 68. This insures that the clamping yokes are in clamping engagement with the bottom flange 64 of the flask 23 and that the draw support frame 67 is in its lowest-most position as identified in FIG. 4. At this time, the counterweights 88 act to insure that the end portions 94 of the latching bars 86 have brought shoulders 92 into engagement in the slots 93. The weight action of the counterweights 88 causes pivotal movement of the bars 86 around pivot point 87 of the latch bars in the direction of arrow 99. Thus, the draw support frame 67 has been placed in extended locked position relative to the pattern-carrying cart 14 thereby insuring secured engagement of the flask 23 to the pattern plate 65. The entire process from this point is repeated as the cart proceeds on to the compacting station to have the molding material deposited within the flask and thereafter compacted to the desired compacted degree.

From the foregoing description, it can be readily seen that the molding apparatus 1 provides a continuously moving molding machine utilizing a closed loop conveyor 13 wherein the top portion 4 of the conveyor passes through the roller compacting means for the purposes of compressing the molding material within the flask to a predetermined pressure, whereas the bottom portion 5 of the conveyor is provided with structural means for downward drawing of the flask with the formed mold in aligned relationship relative to the pattern-carrying cart for depositing of the flask on a draw conveyor positioned directly below the closed loop conveyor 13. Such a structural apparatus provides for a continuous molding operation utilizing the minimum of foundry space.

I claim:

l. A molding apparatus comprising a main support frame, compacting roller means supported on said main frame, a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted on said conveyor frame and comprising a plurality of consecutively connected pattern-carrying carts, supply means adjacent said top portion to apply a mold flask on each of said carts and to deposit molding material in said flask, said compacting roller means comprising two compacting rollers positioned in tandem arrangement and supported above said conveyor frame, arcuate compacting feet disposed on the circumference of each of said compacting rollers with tamping ribs positioned along each of the arcuate surfaces of the first compacting roller feet, synchronizing drive means connected to drive said compacting rollers and said closed loop conveyor in timed correlation so that the rotational velocity of said compactor rollers relative to the lineal passage of said carts therebeneath provides for the passage of each of said compacting feet within the limits of said flask, and second supply means positioned between said compacting rollers for depositing additional molding material in said flask.

2. The molding apparatus of claim 1 characterized by an additional molding apparatus of the type claimed positioned adjacent to the first molding apparatus to produce a mold part adapted to be received by a mold part produced on said first molding apparatus.

3. A molding apparatus comprising a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted on said conveyor frame including a plurality of consecutively connected pattern-carrying carts, means connected through and to each of said carts adapted to releasably secure and retain in aligned position a flask on said carts when said carts are traveling along said conveyor top and bottom portions, means to lower said flasks from said carts to a lowered position without releasing the same by said first-mentioned means when said carts are traveling along said conveyor bottom portion, and means to detach said lowered flasks from said carts.

4. A molding apparatus comprising a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted and driven on said conveyor frame including a plurality of consecutively connected pattern-carrying carts, means for each of said carts adapted to secure and retain a flask in engaged position on said cart, means connected to each of said carts to downwardly draw each of said flasks away from its respective cart in aligned relation to a lowered position below said carts while supported by said securing means when said carts are traveling along said conveyor bottom portion, and means to release said securing means so that said drawing means will lower said flask when said carts commence traveling along said conveyor bottom portion.

5. The molding apparatus of claim 4 characterized by means to control the rate of downward descent of said flask upon operation of said release means.

6. The molding apparatus of claim 5 characterized by fluid control means connected between said carts and said drawing means to control the descent of said flask at a predetermined, controlled rate.

7. The molding apparatus of claim 5 characterized by an air cylinder and piston arrangement comprising said fluid control means and an exhaust port means connected to said cylinder to vary the rate of expulsion of air from within said cylinder upon drawing of said flask from each of said carts.

8. The molding apparatus of claim 4 characterized by cushioning means connected between each of said carts and said drawing means to control the rate of descent of said flask upon operation of said release means.

9. The molding apparatus of claim 4 characterized by a counterweight included in said release means operative by gravity to release said securing means.

10. The molding apparatus of claim 4 characterized in that said securing and drawing means includes a draw support frame beneath each of said carts, at least one pair of draw rods with one pair of their ends attached to said draw support frame and slidably secured to said carts, clamping yokes secured to the other pair of ends of said rods to hold said flask in engagement with said cart.

11. The molding apparatus of claim characterized by means to lock said draw support frame in its extended position from each of said carts to cause said clamping yokes to engage and retain said flask on its respective cart.

12. The molding apparatus of claim 10 characterized by two pairs of draw rods wherein one end of each rod is secured to a corner of said draw support frame, said rods slidable through corresponding sleeves provided in each of said carts with the other ends of said rods having clamping yokes to hold said flask in engagement with its respective cart.

13. The molding apparatus of claim 10 characterized by cam means on said conveyor frame to rotate said rods and withdraw said clamping yokes from beneath said flask when the latter is in said lowered position.

14. The molding apparatus of claim 10 characterized by cam means on said conveyor frame to rotate said rods and thereby engage said clamping yokes onto a flask deposited on a cart when traveling along said conveyor top portion.

15. The molding apparatus of claim 10 characterized by tubular sleeves provided in each of said carts adapted to slidably receive said rods.

16. The molding apparatus of claim 4 characterized by means to withdraw said securing means from their position of retaining said flask when the latter is in said lowered position.

17. The molding apparatus of claim 16 characterized by a second conveyor positioned beneath said closed loop conveyor to receive said flasks when the latter are in said lowered position upon withdrawal of said securing means.

18. The molding apparatus of claim 16 characterized in that said second conveyor is a belt driven conveyor moving at traveling rate substantially equal to the rate of movement of said closed loop conveyor.

19. The molding apparatus of claim 4 characterized by means to lock said drawing means in extended position from its respective cart to cause said securing means to retain said flask in engagement therewith.

20. The molding apparatus of claim 4 characterized by means to align said securing means for clamping engagement of a flask deposited on a respective cart when the latter commences traveling along said conveyor top portion. 

1. A molding apparatus comprising a main support frame, compacting roller means supported on said main frame, a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted on said conveyor frame and comprising a plurality of consecutively connected patterncarrying carts, supply means adjacent said top portion to apply a mold flask on each of said carts and to deposit molding material in said flask, said compacting roller means comprising two compacting rollers positioned in tandem arrangement and supported above said conveyor frame, arcuate compacting feet disposed on the circumference of each of said compacting rollers with tamping ribs positioned along each of the arcuate surfaces of the first compacting roller feet, synchronizing drive means connected to drive said compacting rollers and said closed loop conveyor in timed correlation so that the rotational velocity of said compactor rollers relative to the lineal passage of said carts therebeneath provides for the passage of each of said compacting feet within the limits of said flask, and second supply means positioned between said compacting rollers for depositing additional molding material In said flask.
 2. The molding apparatus of claim 1 characterized by an additional molding apparatus of the type claimed positioned adjacent to the first molding apparatus to produce a mold part adapted to be received by a mold part produced on said first molding apparatus.
 3. A molding apparatus comprising a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted on said conveyor frame including a plurality of consecutively connected pattern-carrying carts, means connected through and to each of said carts adapted to releasably secure and retain in aligned position a flask on said carts when said carts are traveling along said conveyor top and bottom portions, means to lower said flasks from said carts to a lowered position without releasing the same by said first-mentioned means when said carts are traveling along said conveyor bottom portion, and means to detach said lowered flasks from said carts.
 4. A molding apparatus comprising a horizontal conveyor frame having a top portion and a bottom portion, a closed loop conveyor mounted and driven on said conveyor frame including a plurality of consecutively connected pattern-carrying carts, means for each of said carts adapted to secure and retain a flask in engaged position on said cart, means connected to each of said carts to downwardly draw each of said flasks away from its respective cart in aligned relation to a lowered position below said carts while supported by said securing means when said carts are traveling along said conveyor bottom portion, and means to release said securing means so that said drawing means will lower said flask when said carts commence traveling along said conveyor bottom portion.
 5. The molding apparatus of claim 4 characterized by means to control the rate of downward descent of said flask upon operation of said release means.
 6. The molding apparatus of claim 5 characterized by fluid control means connected between said carts and said drawing means to control the descent of said flask at a predetermined, controlled rate.
 7. The molding apparatus of claim 5 characterized by an air cylinder and piston arrangement comprising said fluid control means and an exhaust port means connected to said cylinder to vary the rate of expulsion of air from within said cylinder upon drawing of said flask from each of said carts.
 8. The molding apparatus of claim 4 characterized by cushioning means connected between each of said carts and said drawing means to control the rate of descent of said flask upon operation of said release means.
 9. The molding apparatus of claim 4 characterized by a counterweight included in said release means operative by gravity to release said securing means.
 10. The molding apparatus of claim 4 characterized in that said securing and drawing means includes a draw support frame beneath each of said carts, at least one pair of draw rods with one pair of their ends attached to said draw support frame and slidably secured to said carts, clamping yokes secured to the other pair of ends of said rods to hold said flask in engagement with said cart.
 11. The molding apparatus of claim 10 characterized by means to lock said draw support frame in its extended position from each of said carts to cause said clamping yokes to engage and retain said flask on its respective cart.
 12. The molding apparatus of claim 10 characterized by two pairs of draw rods wherein one end of each rod is secured to a corner of said draw support frame, said rods slidable through corresponding sleeves provided in each of said carts with the other ends of said rods having clamping yokes to hold said flask in engagement with its respective cart.
 13. The molding apparatus of claim 10 characterized by cam means on said conveyor frame to rotate said rods and withdraw said clamping yokes from beneath said flask when the latter is in said lowered position.
 14. The molding apparatus of claim 10 characterized by cam means on said conveyOr frame to rotate said rods and thereby engage said clamping yokes onto a flask deposited on a cart when traveling along said conveyor top portion.
 15. The molding apparatus of claim 10 characterized by tubular sleeves provided in each of said carts adapted to slidably receive said rods.
 16. The molding apparatus of claim 4 characterized by means to withdraw said securing means from their position of retaining said flask when the latter is in said lowered position.
 17. The molding apparatus of claim 16 characterized by a second conveyor positioned beneath said closed loop conveyor to receive said flasks when the latter are in said lowered position upon withdrawal of said securing means.
 18. The molding apparatus of claim 16 characterized in that said second conveyor is a belt driven conveyor moving at traveling rate substantially equal to the rate of movement of said closed loop conveyor.
 19. The molding apparatus of claim 4 characterized by means to lock said drawing means in extended position from its respective cart to cause said securing means to retain said flask in engagement therewith.
 20. The molding apparatus of claim 4 characterized by means to align said securing means for clamping engagement of a flask deposited on a respective cart when the latter commences traveling along said conveyor top portion. 